Last Updated on March 26, 2023 by admin
A cable lug is a standard electrical component that attaches the cable to the device terminals, making personnel assembly, maintenance, and repair. A cable lug or adapter is utilized when a persistent connection is necessary, but a direct connection is unpleasant or impossible to accomplish.
Lugs are available in various diameters & mounting holes, with wire size varying from #8AWG to 1000MCM, and are manufactured of high-grade electrolytic copper (ETP Grade). The connections have corrosive environment tin plating, CSA, and UL certified.
What are the different types of lugs?
Lugs are mechanical fasteners used to secure two or more components together. There are many different lugs, each with unique features and benefits. The most common are eye lugs, U-bolts, J-bolts, and square lugs. Eye lugs are shaped like a loop and are commonly used to attach ropes or chains. U-bolts are curved and commonly used to clamp pipes or rods.
J-bolts have a J-shaped design and are often used for foundation anchors or construction applications. Square lugs are box-like and commonly used in electrical applications to secure cables or wires. Specialized lugs, such as V-lugs or T-lugs, are also designed for specific applications or industries. The type of lug used will depend on the application’s specific requirements, such as the weight being supported, the environment, and the fastened material.
Lug of aluminum
Aluminum lugs are made from a solid aluminum rod with high thermal conductivity (99.6% pure) aluminum content. The lugs are made of solid metal and suited for outdoor usage (as the palm ends are sealed). Jointing compounds are included in the barrels of the Aluminum Lugs, which are then capped with an end cap. Crimping is done with hex dies & standard aluminum cable.
Copper lugs are helpful for power draw or grounding in large gauge applications. Each copper lug can be connected or crimped with the wire. One extremity of the copper lug solders, welds, or crimps the cable depending on the lug used. A bolt, clamp, or spring clip secures the other extremity of the copper lug to a corresponding termination or connecting point. Copper Cable Lugs are simple to install and dependable over time. Copper lugs from AXIS are composed of high-grade ETP copper and are tinned for corrosion resistance. Excellent for use in the outdoors or aquatic organisms.
AXIS Copper Lugs are serviceable with rapid cancellation techniques for connecting multiple heavy gauge power lines to transmission lines, relays, batteries, solar energy inverters, electrical cables, earthing system devices, and also more, with improved efficiency, protection, and reduced costs, with cable various sizes from 1.5 sq. mm to 1000 sq. mm.
Lugs made of two metals
The most significant quality attachment between the copper palm and the aluminum barrel is established by AXIS-oriented bimetallic lugs formed by friction welding. Bimetallic Lugs are used in Solar Plants to link aluminum conductors to copper busbars in various electrical applications like control panels, switchgear, and concatenation boxes. The aluminum barrel is pressure soldered to the metal palm, resulting in the best conceivable barrel-to-palm transition.
Consequently, the aluminum conductors come into contact with the aluminum barrels, while the copper busbar comes into contact with the copper palm. The lug barrel is coated with contact lubricant to avoid oxidation and increase contact characteristics, allowing for a smooth electronic circuit.
Lugs for crimping
Crimping is the deformation of either one of two metal plates or similar material to keep the other in place. Crimp is the term for bent or malformation. Crimping lugs allow cables, materials, and machinery to be connected. Crimping lugs are the clamps that connect wires to an automobile battery and the terminals of battery jumper cables.
All used vehicle wire networks, electrical boxes, industrial, household items, electronics, and other long-lasting goods. Rubber or plastic should be used to insulate electrical applications. They prevent energy transfer to people or other electronic systems by mistake.
The best-fit approach for attaching cable conductors is shear-off bolted connectors are used in mechanical connector innovation. At a preset torque, the screw head is sheared off. Specific alloys are used in mechanical interconnections or shear bolt connectors.
Sleeves and lug bodies of an elevated aluminum alloy make up these connectors. The connections’ inside surfaces are grooved, and also the sleeves are suited for usage underground. Lugs come in various palm hole sizes and can be worn inside and out. Low voltage, power quality, and large electrical versions of these goods are also available.
Mechanical vs. compression lugs
Compression lugs are for modest electrical works & mechanical components for large (buildings or large scale commercial cables). Mechanical lugs are much larger than compression lugs. Large cables, such as cable wires, are connected by mechanical lugs.
They are being used in automobiles due to their construction and design. Compressive lugs are typically seen in homes and small businesses when cable connectors are required.
Comparison of copper and aluminum lug
Copper lugs are superior in several respects, although they are more costly than aluminum lugs. Aluminum cables and lugs are used in practically every wiring system due to their inexpensive cost. Aluminum lugs are undergoing technological advancements to make them as safe and efficient as copper lugs.
Aluminum lugs are anodized with an inner part of copper covering for corrosion resistance and have chamfered barrel entrance ends for straightforward insertion. The lug’s inner barrel contains an AntiOxide compound, which inhibits oxide formation inside the lug and aids in obtaining a good connection after crimping the lug to the conductor; nonetheless, UL listed aluminum lugs bear the AL9CU designation.
Features of different lugs
- There is a technical pull-out test and an electrical durability test for accessing the wire barrel. The shockproof sections of the entryway are bell-mouthed, permitting the conductors to be inserted smoothly.
- The cable lugs have been through extensive current examinations at temperature changes of 250°C. High-quality materials offer improved conductivity, carrying capacity, & durability.
- A simple and secure system is connected possible by flat contact area and an inner chamfer. Copper lugs are annealing to a specified temperature to enhance material characteristics and crimping.
- All copper components are electro-tinned to BS requirements, which resist corrosion & oxidation, and terminals coated with PVC provide excellent dielectric protection and stiffness.
How should you pick cable lugs?
The conductor class that has to be processed affects how to choose the appropriate cable lug. As an example, cables in compliance with DIN EN 60228 can be protected by the following compression cable lugs: class 1, 2, 5, and 6 conductors: DIN 46235-compliant cable lugs. Tubular cable lugs of the standard style for class 2 wires.